Child-Resistant Containers Having Spinning Collar Cap Assemblies And Methods For The Manufacture Thereof

ABSTRACT

Child-resistant containers or packages having spinning collar cap assemblies are provided, as are methods for manufacturing such containers. In various embodiments, the child-resistant container includes a container body having an inner cavity, an opening to the inner cavity, and a container neck circumscribing the opening. A spinning collar is retained around the container neck and is rotatable relative thereto in at least a first rotational direction. The child-resistant container further includes an overcap, which is sized and shaped to enclose the opening when attached to the spinning collar. Through the provision of a suitable threaded interface the overcap can be (i) detached from the spinning collar by rotation of the overcap relative to the spinning collar in the first rotational direction and (ii) removably attached to the spinning collar by rotation of the overcap relative to the spinning collar in a second rotational direction opposite the first rotational direction.

FIELD OF THE INVENTION

Embodiments of the present invention relate generally to child-resistantpackaging and, more particularly, to child-resistant containers havingspinning collar cap assemblies, as well as to associated manufacturingmethods.

BACKGROUND OF THE INVENTION

A child-resistant package is designed to reduce the ease with whichchildren are able to access the contents stored within the package. Apill bottle or similar molded plastic container having a neck, forexample, may be rendered child resistant through the usage of aspecialized cap, which is attachable to the container neck. Jointly, thecontainer neck and the cap form a child-resistant cap assembly, whichrequires the performance of certain actions to detach the cap from thecontainer neck. The cap and container neck may engage along a threadedinterface, in which case cap removal may be prevented by obstructingrotation of the cap relative to the container neck in some manner. Forexample, in one common design, the cap is molded to include flexibletabs located about the periphery of the cap. Cap rotation relative tothe container neck is obstructed unless the tabs are depressed inwardlyby an adult user, while the user simultaneously turns the cap in theappropriate direction. In another common design, removal of a threadedcap is prevented unless the cap is turned in the correct direction,while pressed downwardly toward the container body. In other instances,a child-resistant cap assembly may lack a threaded interface between thecap and container neck, in which case cap removal may be restrictedutilizing a different approach. For example, in this latter case, thecap assembly may be designed such that cap removal is possible onlyafter rotation of the non-threaded cap to a particular angular positionor clocking relative to the container body.

While often relatively non-complex in a structural sense,child-resistant cap assemblies can be deceptively difficult to design.An inexorable tradeoff is encountered in designing a child-resistant capassembly that the vast majority of adults (including the elderly andthose with disabilities) find intuitive and relatively non-cumbersome touse, while most children find prohibitively difficult to open.Relatively few, if any conventional child-resistant cap assembliesstrike an ideal balance between these competing factors. There thusexists an ongoing demand for child-resistant cap assemblies providingenhanced child deterrence characteristics, while further maintaining orimproving adult ease-of-use. Concurrently, it would be desirable forsuch child-resistant cap assemblies to be amenable to cost effectivemanufacture and, perhaps, capable of relatively seamless incorporationinto legacy product lines and manufacturing practices.

BRIEF SUMMARY OF THE INVENTION

Embodiments of a child-resistant container or package having a spinningcollar cap assembly are provided. In various embodiments, thechild-resistant container includes a container body having an innercavity, an opening to the inner cavity, and a container neckcircumscribing the opening. A spinning collar is retained around thecontainer neck and rotatable relative thereto in at least a firstrotational direction. An overcap is sized and shaped to enclose theopening and thereby block access to the inner cavity when the overcap isattached to the spinning collar. The child-resistant container furtherincludes a threaded interface, which is provided between the spinningcollar and the overcap. The threaded interface enables the overcap to be(i) detached from the spinning collar by rotation of the overcaprelative to the spinning collar in the first rotational direction and(ii) removably attached to the spinning collar by rotation of theovercap relative to the spinning collar in a second rotational directionopposite the first rotational direction. In implementations in which thespinning collar is rotatable with respect to the container neck in thefirst rotational direction through a 360 degree range of motion, thespinning collar may co-rotate with the overcap when turned in the firstrotational direction and rotation of the spinning collar is manuallyundeterred; that is, the spinning collar is not grasped or otherwisephysically contacted by a user in a manner preventing rotation of thecollar in conjunction with rotation of the overcap.

Embodiments of a child-resistant cap assembly are further provided. Inone embodiment, the child-resistant cap assembly includes a spinningcollar and an overcap, which has threaded inner surface. The spinningcollar includes, in turn, an annular collar body, which is sized andshaped for installation around a container neck, such as the neck of amolded bottle, which has an outer circumferential channel. A threadedouter surface is provided around an outer periphery of the annularcollar body. The threaded outer surface of the spinning collarcooperates or combines with the threaded inner surface of the overcap toenable the overcap to be removably attached to the spinning collar byrotation of the overcap relative to the spinning collar in a firstrotational direction (e.g., the below-described twist-on direction). Aretention feature, such as a snap lug, projects from the annular collarbody in a radially inward direction; that is, in a directionsubstantially perpendicular to a centerline of the annular collar body.The retention feature is configured (sized and shaped) to engage intothe outer circumferential channel to retain the spinning collar aroundthe container neck, while permitting rotation of the spinning collarrelative to the container neck in a second rotational direction (e.g.,the below-described twist-off direction) opposite the first rotationaldirection.

Methods for manufacturing a child-resistant package are still furtherprovided. In one embodiment, the method includes the step or process ofinstalling a spinning collar around the container neck of a package orcontainer, such as a molded plastic bottle. Installation is performedsuch that the spinning collar is retained around the container neck,while relative rotation of the collar and container neck is permitted inat least in a first rotational direction. An overcap is removablyattached to the spinning collar by placing a threaded inner surface ofthe overcap in contact with a threaded outer surface of the spinningcollar and rotating the overcap relative to the spinning collar in asecond rotational direction opposite the first rotational direction. Incertain implementations, the spinning collar may be installed around thecontainer neck by press-fitting. During press-fitting, a snap lug orother projection provided on the spinning collar may contact and slideover a neck bead, which extends at least partially around an outerperiphery of the container neck, such that the projection engages intoan outer circumferential channel further provided around the containerneck.

The foregoing statements are provided by way of non-limiting exampleonly. Various additional examples, aspects, and other features ofembodiments of the present disclosure are encompassed by the presentdisclosure and described in more detail below.

BRIEF DESCRIPTION OF THE DRAWINGS

At least one example of the present invention will hereinafter bedescribed in conjunction with the following figures, wherein likenumerals denote like elements, and:

FIG. 1 is a disassembled or exploded isometric view of a child-resistantcontainer including a spinning collar cap assembly, as illustrated inaccordance with an exemplary embodiment of the present disclosure;

FIG. 2 is an assembled isometric view of the exemplary child-resistantcontainer shown in FIG. 1 illustrating one manner in which the overcapof the cap assembly can be manually detached from the spinning collar toprovide adult access to the interior of the container and any contentsstored therein; and

FIG. 3 illustrates the child-resistant container shown in FIGS. 1-2 withthe addition of a tamper evident tear strip, as further depicted with anexemplary embodiment of the present disclosure.

For simplicity and clarity of illustration, descriptions and details ofwell-known features and techniques may be omitted to avoid unnecessarilyobscuring the exemplary and non-limiting embodiments of the inventiondescribed in the subsequent Detailed Description. It should further beunderstood that features or elements appearing in the accompanyingfigures are not necessarily drawn to scale unless otherwise stated.

DETAILED DESCRIPTION OF THE INVENTION

The following Detailed Description is merely exemplary in nature and isnot intended to limit the invention or the application and uses of theinvention. The term “exemplary,” as appearing throughout this document,is synonymous with the term “example” and is utilized repeatedly belowto emphasize that the following description provides only multiplenon-limiting examples of the invention and should not be construed torestrict the scope of the invention, as set-out in the Claims, in anyrespect.

Overview

Child-resistant containers including spinning collar cap assemblies areprovided, as are methods for manufacturing such cap assemblies.Generally, the child-resistant containers described herein and,particularly, the spinning collar cap assemblies restrict access to thepackage contents in a manner providing effective child deterrence, whilefurther ensuring adult ease-of-use. This is principally accomplishedthrough the provision of a spinning collar, which is secured around aneck portion of the container in a manner allowing relative rotationbetween the collar and the container neck in at least a first rotationaldirection and through a 360 degree)(° angular range of motion (ROM). Anovercap or lid can be attached to the spinning collar in a mannerphysically covering an opening circumscribed by the container neck,thereby enclosing container's interior and preventing access to thecontents stored therein. In various embodiments, the overcap andspinning collar engage along a threaded interface, which allows removalof the overcap by rotation of the overcap relative to the spinningcollar in the first rotational direction. For ease of reference, thisrotational direction is referred to herein as the “twist-off” direction,while the opposing rotational direction is referred to herein as the“twist-on” direction. By widespread design practices, the twist-off andtwist-on directions will typically correspond to counter-clockwise andclockwise directions, respectively, although this relationship can bereversed if so desired; that is, the twist-on and twist-off directionsmay respectively correspond to clockwise and counter-clockwisedirections in alternative embodiments.

As the spinning collar is able to freely rotate relative to thecontainer neck in the twist-off direction through a 360° ROM, rotationof the spinning collar in this direction remains undeterred when simplygrasping the body of the child-deterrent container, as may beintuitively done by child. Consequently, a child attempting to open thechild-deterrent container by grasping the container body and attemptingto rotate the overcap in the twist-off direction will be unable toremove the overcap and gain access to the container's contents. In thisinstance, the overcap and the spinning collar will co-rotate relative tothe container body, while the overcap remains securely attached to thecontainer neck. The co-rotation of the overcap and spinning collar may,in effect, create a diversion or decoy at least temporarily delayingfurther efforts by the child to gain access to the container.Additionally, the spinning collar cap assembly can be designed such thatthe spinning collar is visually deemphasized to many children and,therefore, less likely to be firmly grasped by a child when attemptingto remove the overcap.

To detach the overcap from the spinning collar and gain access to thecontainer interior, an adult user is required to both rotate the overcapin the twist-off direction, while manually preventing rotation of thespinning collar relative to the overcap. To enable a user to manuallyprevent rotation of the collar, the spinning collar is imparted with amanual grip portion that can be grasped or otherwise manually contactedby an adult user from the exterior of the child-resistant container whenthe cap assembly is closed. Various design aspects of the manual gripportion can be tailored to render the cap assembly relativelychallenging for the vast majority of children to defeat or bypass, whilemaintaining a desired level of ease-of-use for adults. Additionally,other features may be included in the child-deterrent cap assembly forimproving child deterrence or enhancing adult ease-of-use. For example,in certain implementations, the child-deterrent cap assembly may furtherinclude a unidirectional rotational interface between the spinningcollar and the container neck. When provided, the unidirectionalrotational interface prevents rotation of the spinning collar relativeto the container neck (and, more generally, the container body) througha ROM less than 360° in the twist-on direction. This, in turn, may allowan adult user to reattach the overcap by rotating the overcap in thetwist-on direction, while holding the container body. Adult ease-of-useis enhanced as a result, while consistent reattachment of the overcap isencouraged to help ensure that the child deterrent mechanism of the capassembly is reset after container access.

Embodiments of the spinning collar cap assembly are amenable tocost-effective manufacture and, in certain cases, may be incorporatedinto existing product lines in a relatively seamless manner. Forexample, in implementations, the spinning collar can be structurallyconfigured (sized and shaped) for compatibility with so-called “snaplid” neck finishes, which have gained widespread market adoption.Generally snap lid neck finishes feature a raised lip or “snap bead,”which extends partially around an outer circumference of the containerneck for usage in conjunction with a corresponding snap lid. Thespinning collar may be structurally configured to adapt to such a snaplid neck finish, in embodiments, and may further include various uniquefeatures cooperating with the neck finish to provide the uniquefunctionalities. Additionally, in certain instances, a given snap lidneck finish may be modified to include other non-conventional features,such as snap lug features of the type described below. Advantageously,such features can be often incorporated into existing tooling or moldsthrough relatively minor (e.g., metal safe) modifications. Thisnotwithstanding, the spinning collar cap assembly may cooperate with orinclude a container neck having a different type of neck finish in otherembodiments. An exemplary embodiment of a child-resistant containerincluding spinning collar cap assembly will now be described inconjunction with FIGS. 1-3.

Example of a Child-Resistant Container Including a Spinning Collar CapAssembly

FIG. 1 is a disassembled or exploded isometric view of a child-resistantcontainer 10 including a spinning collar cap assembly 12, as illustratedin accordance with an exemplary and non-limiting embodiment of thepresent disclosure. Child-resistant container 10 includes a vessel orcontainer body 14, only the upper portion of which is shown. In thisparticular example, container body 14 assumes the form of a moldedplastic bottle, which is well-suited for holding single use detergentcapsules. It is emphasized, however, that the particular form factor ofcontainer body 14 and the contents of container 10 will vary amongembodiments. Spinning collar cap assembly 12 can be utilized inconjunction with or incorporated into various different types ofchild-resistant containers, without limitation, and with the bottlecontainer shown in FIG. 1 being but one suitable example. Moreover, theparticular contents or materials held within container 10 are generallyinconsequential to the present disclosure and can include pill-formmedication, as well as various other items, depending upon theparticular size, shape, and composition of container body 14.

An inner cavity 16 is located within the interior of container body 14.A throat or opening 18 is provided in the upper end portion of body 14to allow physical access to cavity 16 when cap assembly 12 is opened. Acontainer neck 20 extends from container body 14 to circumscribe orperipherally bound opening 18. In the illustrated example, containerbody 14 and container neck 20 are integrally formed as a single (e.g.,blow molded) piece. In further embodiments, container body 14 andcontainer neck 20 can be separately fabricated from the same, similar,or dissimilar materials, and subsequently joined in some manner. Forexample, in one implementation, container neck 20 can be fabricated as ablow molded, injection molded, or additively-manufactured piece, whilecontainer body 14 is separately produced as a non-rigid structure (e.g.,a flexible bag or collapsible vessel) to which container neck 20 issubsequently attached. Various other constructions are also possible.While such a structural design will generally be less common than thatshown in FIG. 1, this is nonetheless noted to further emphasize thatspinning collar cap assembly 12 is highly adaptable and can beincorporated into an essentially limitless range of packaging types.Container neck 20 may be considered part of spinning collar cap assembly12 in at least some embodiments of child-resistant container 10.

In addition to container neck 20, spinning collar cap assembly 12includes a spinning collar 22 and a lid piece or overcap 24. Spinningcollar 22 is retained around container neck 20 when spinning collar capassembly 12 is assembled, as shown in FIG. 2. Comparatively, overcap 24can be removably attached to spinning collar 22, when desired, toenclose opening 18 and prevent physical access to inner cavity 16.Overcap 24 can be removed or detached from spinning collar 22 to exposeopening 18 and provide access to inner cavity 16 when certain steps orphysical actions are performed by an adult user. As indicated by thedescriptor “spinning,” collar 22 is capable of 360° rotation (that is,rotation over and through a 360° ROM) relative to container neck 20 inat least one rotational direction, as taken about a rotational axisrepresented in FIG. 2 by dashed line 28. Stated differently, spinningcollar 22 is rotatable relative to container neck 20 about axis 28through any number of complete, 360° revolutions in at least onerotational direction; again, referred to herein as the “twist-off”direction. As noted above, and as indicated in FIG. 2 by arrow 26, thetwist-off direction will typically (but does not necessarily) correspondto a counter-clockwise direction. In certain implementations, spinningcollar 22 may likewise be capable of 360° rotation relative to containerneck 20 in the opposing rotational direction (the “twist-on” direction).It is generally desirable, however, to prevent rotation of spinningcollar 22 through a 360° ROM relative to container neck 20 in thetwist-on direction to facilitate overcap reattachment. Accordingly, inembodiments, spinning collar 22 may be rotatable relative to neck 20 inthe twist-on direction, but through an angular ROM less than 360°.

As shown most clearly in FIG. 2, spinning collar cap assembly 12 may bedesigned such that rotational axis 28 is substantially coaxial with therespective centerlines of container neck 20 and spinning collar 22, asconsidered when spinning collar cap assembly 12 is fully assembled andclosed. The respective centerlines of container neck 20 and spinningcollar 22 may also be aligned or positioned in a substantially co-axialrelationship when spinning collar cap assembly 12 is assembled andclosed. Accordingly, dashed line 28, as shown in FIG. 2, may beconsidered to further represent the respective centerlines of containerneck 20 and spinning collar 22. Spinning collar 22 may also be describedas freely rotatable through a 360° ROM with respect to container neck 20in the twist-off direction, as taken about the centerline of collar 22or about the centerline of neck 20.

A collar retention interface 30, 32, 34 is formed between container neck20 and spinning collar 22. Collar retention interface 30, 32, 34 canassume any structural form and include any number and type of structuralfeatures serving to physically retain or capture spinning collar 22about container neck 20, while permitting collar 22 to rotate relativeto neck 20 in at least the twist-off direction. In the illustratedexample, collar retention interface 30, 32, 34 includes an annular ribor snap bead 30, which extends around a majority of an outer peripheryof container neck 20. Specifically, snap bead 30 extends around theperiphery of container neck 20 in its substantial entirety, with theexception of angular gap 36. Angular gap 36 may span, for example, a 5°to 20° angular range, as taken about rotational axis 28. Angular gap 36is generally unneeded in the illustrated example from a functionalstandpoint, but is shown to emphasize the relative ease with which capassembly 12 can be utilized in conjunction with existing snap lid neckfinishes, which may or may not be modified to varying extents.

As stated above, container neck 20 is imparted with a snap lid neckfinish in the illustrated embodiment. Setting aside certainmodifications, the snap lid neck finish shown in FIGS. 1-2 is generallysimilar to an existing design, which has gained widespread marketadoption. The general design of container neck 20 may thus have beenintended, originally, for usage in conjunction with a correspondingsnap-fit lid or, more simply, a “snap lid.” Snap lids of this type arecommercially available and typically include an inner projection or key,which extends radially inwardly from an inner periphery or innerdiameter (ID) of the cap sidewall. To remove the snap lid from containerneck 20, an adult user rotates the lid to align the projection or keywith angular gap 36, which serves as a keyway or passageway. The userthen exerts an upwardly lifting force, typically with his or her thumb,to remove the snap lid from neck 20 in a prying motion. In the presentexample, spinning collar cap assembly 12 has supplanted or replaced sucha snap lid, in part by leveraging pre-existing snap bead 30 to retainspinning collar 22 around container neck 20.

Snap bead 30 cooperates with a lower annular shelf or ridge 38, whichfurther extends around an outer periphery or outer diameter (OD) ofcontainer neck 20, to define an annular groove or outer circumferentialchannel 32 around neck 20. Spinning collar 22 further includes at leastone inner protrusion, projection, or snap lug 34, which is receivedwithin outer circumferential channel 32 when collar 22 is installedaround container neck 20. As shown most clearly in FIG. 1, snap lug 34extends from an inner peripheral surface of spinning collar 22 in aradially inward direction. The term “radial,” as appearing herein, isdefined as a direction perpendicular to centerline 28 of spinning collar22 (or to the centerline of container neck 20, as will be clear fromcontext). In the illustrated example in which snap bead 30 isinterrupted by annular gap 36, snap lug 34 is usefully imparted with alength or span, as measured about the centerline of collar 22, exceedingthe length or span of gap 36, as measured about the centerline of neck20.

By virtue of the above described structural arrangement, undesiredremoval of spinning collar 22 is prevented (or at least renderedunreasonable for the user, in a practical sense) following assembly ofspinning collar cap assembly 12. Further, spinning collar 22 issufficiently flexible and dimensioned to enable collar 22 to bepress-fit onto container neck 20 during original manufacture andassembly. When spinning collar 22 is press-fit onto container neck 20during assembly, snap lug 34 contacts and slides over snap bead 30before engaging into outer circumferential channel 32. Followingengagement of snap lug 34 into circumferential channel 32, removal ofspinning collar 22 from container neck 20 is obstructed by abutment ofsnap lug 34 against snap bead 30. The respective materials, dimensions,and sloped contours of snap lug 34 and snap bead 30 can be tailored toreadily allow such a snap fit action, while securely retaining collar 22around container neck 20 following assembly.

Spinning collar 22 has a substantially annular, tubular, or ring-shapedbody through which a central opening 40 is provided. The body ofspinning collar 22 is dimensioned such that an upper portion ofcontainer neck 20 can be received through central opening 40 in arelatively close-fitting relationship. Additionally, as noted above,spinning collar 22 and container neck 20 are usefully imparted withcertain unidirectional rotation features preventing or at leasthindering rotation of collar 22 relative to neck 20 (and, more broadly,container body 14) through a ROM less than 360° in the twist-ondirection. For example, as best shown in FIG. 1, spinning collar 22 maybe further imparted with at least one ratchet lug 42, which extendsradially inward from an inner periphery of collar 22. Similarly,container neck 20 may additionally feature a corresponding ratchet lug44, which extends radially outward from an outer periphery of containerneck 20. In the depicted embodiment, ratchet lug 44 is located withinouter circumferential channel 32 and may be positioned closer to annularridge 38 than to snap bead 30, as taken along the centerline of neck 20(again, corresponding to dashed line 28 in FIG. 2). Comparatively,ratchet lug 42 may be located proximate or adjacent a lower peripheraledge of spinning collar 22 and, perhaps, located closer to the lowerperipheral edge of collar 22 than is snap lug 34.

Ratchet lugs 42, 44 are contoured (e.g., imparted with ramp-likegeometries) such that, when ratchet lugs 42, 44 are brought into contactby rotation of spinning collar 22 relative to container neck 20 in thetwist-off direction, collar 22 and/or neck 20 deflect to allow ratchetlug 42 to slide over and past ratchet lug 44. This, in turn, permitsfull, 360° rotation of spinning collar 22 relative to container neck 20in the twist-off direction; that is, rotation of collar 22 relative toneck 20 over and through a 360° ROM. Conversely, ratchet lugs 42, 44 areshaped and dimensioned such that, when brought into contact by rotationof spinning collar 22 relative to container neck 20 in the twist-ondirection, the relatively flat or non-ramped ends of ratchet lugs 42, 44abut to prevent further relative rotation of collar 22 and neck 20.Stated differently, ratchet lug 42 abuts ratchet lug 44 to create aphysical impasse when spinning collar 22 is rotated relative tocontainer neck 20 in the twist-off direction.

Ratchet lugs 42, 44 thus cooperate or combine to obstruct complete, 360°rotation of spinning collar 22 relative to container neck 20 in thetwist-on direction. This enhances the ease with which overcap 24 can bereattached to spinning collar 22 and, therefore, to container neck 20 byan end user. The number and positioning of ratchet lugs 42, 44 can betailored to prevent rotation of spinning collar 22 relative to containerneck 20 over any angular ROM less than 360° in the twist-on direction.Stated generally, ratchet lugs 42, 44 may cooperate to prevent rotationof spinning collar 22 relative to container neck 20 in the twist-ondirection over, but not beyond an angular ROM of x°, wherein x is lessthan 360°. As a specific, albeit arbitrary example, spinning collar capassembly 12 can contain four ratchet lugs 44, which are angularly spacedabout container neck 20 at regular intervals such that spinning collar22 can be rotated relative to neck 20 over, but not beyond a 90° ROM inthe twist-on direction. Similarly, in another implementation, threeratchet lugs 44 may be angularly spaced about container neck 20 atregular intervals such that collar 22 can be rotated relative to neck 20over, but not beyond a 120° ROM in the twist-on direction. Various otherembodiments are also possible.

In the above-described manner, ratchet lugs 42, 44 cooperate to providea unidirectional rotational interface, which permits rotation ofspinning collar 22 relative to container neck 20 through a 360° ROM inthe twist-off direction, while preventing rotation of collar 22 relativeto neck 20 through an angular ROM less than 360° in the twist-ondirection. This allows a user to reattach overcap 24 to spinning collar22 by rotating overcap 24 in the twist-on direction, while simplygrasping container body 14, rather than requiring the user to grip orhold spinning collar 22 during overcap reattachment. Other types ofunidirectional rotational interfaces are also possible in furtherembodiments. Further, spinning collar cap assembly 12 may lack such aunidirectional rotational interface in alternative implementations, inwhich case a user hold spinning collar 22 when reattaching overcap 24 byrotation in the twist-on direction.

With continued reference to FIGS. 1-2, ratchet lug 44 is a uniquefeature, which is not typically present in conventional snap lid neckfinishes. Ratchet lug 44 can therefore be added by fabrication as adiscrete piece, which is adhesively attached, heat staked, or otherwiseaffixed to neck 20 in implementations. Manufacturing efficiency and costwill typically be enhanced, however, by forming ratchet lug 44 as anative molded feature in embodiments in which container neck 20 (and,more broadly, container body 14) are formed by injection molding. Insuch embodiments, the tool or mold utilized to produce container neck 20and, perhaps, container body 14 can be modified through controlledmaterial removal (e.g., by computer numerical control (CNC) milling) tocreate a negative feature or void, which then defines ratchet lug 44when filled with mold material. In industry terms, this is oftenreferred to as “metal safe” and enables existing tooling to be modifiedto include features, such as ratchet lug 44, in a cost efficient andtimely manner.

Spinning collar cap assembly 12 has been principally described herein asadapted to include or to function with a container neck having apre-existing snap neck finish. Advantageously, this allows incorporationof spinning collar cap assembly 12 into existing product lines or partnumbers with minimal modifications and costs. This notwithstanding,embodiments of spinning collar cap assembly 12 are not limited to usagewith container necks having a snap lid neck finish or with any othertype of conventional neck finish. Instead, spinning collar cap assembly12 can readily be fabricated to include or to cooperate with a containerneck having any shape, dimensions, and structural features allowingspinning collar 22 to be retained therearound in a manner permittingcollar rotation relative to neck 20 in at least the twist-off direction,as discussed throughout this document. Various inverted relationships ofthe structural interfaces presented herein are also contemplated inalternative embodiments; e.g., an annular groove or innercircumferential channel may be provided around an inner periphery ofcollar 22, while snap lug 34 is formed to project outwardly from theouter peripheral surface of container neck 20 and engage into the innercircumferential channel when cap assembly 12 is assembled. As a stillfurther possibility, spinning collar cap assembly 12 may be fabricatedas a plug-type closure. In this latter instance, at least a portion ofspinning collar 22 may extend around an inner periphery of containerneck 20, while the below-described collar-overcap interface is formedalong an inner periphery of collar 22 and an outer periphery of overcap24.

In the illustrated embodiment of FIGS. 1-2, overcap 24 engages spinningcollar 22 via a threaded interface 46, 48. Threaded interface 46, 48 isdefined by a helical thread feature 46 provided around an outerperiphery of collar 22 and a corresponding or mating helical threadfeature 48 provided around an inner periphery of annular sidewall 50 ofovercap 24. Threaded interfaces 46, 48 are imparted with the appropriatephysical characteristics (e.g., handedness and pitch) such that overcap24 can be securely twisted or tightened onto spinning collar 22 toenclose opening 18 and, more generally, the interior of container body14 by rotation of overcap 24 relative to collar 22 in the twist-ondirection. Conversely, threaded interface 46, 48 also allows overcap 24to be removed or detached from spinning collar 22 by relative rotationbetween these components in the twist-off direction. A thread stopfeature 52 may be formed on spinning collar 22 to halt further rotationof overcap 24 relative to collar 22 in the twist-on direction afterovercap 24 has been rotated into its fully closed position.

Spinning collar cap assembly 12 further includes a number of detentfeatures 54, 56, which are formed on spinning collar 22 and overcap 24.As indicated in FIG. 1, at least a first detent feature 54 may be formedon an outer peripheral portion of spinning collar 22, while at least asecond detent feature 56 may be formed on an inner peripheral portion ofovercap 24. Detent features 54, 56 cooperate or combine to provide apredictable, controlled resistance encountered by a user when rotatingovercap 24 into and out of its fully closed position. The resistanceprovided by detent features 54, 56 is also ideally selected, by design,to be sufficient to overcome any frictional forces that would otherwiseprevent relative rotation of spinning collar 22 and container neck 24 inthe twist-off direction. In this manner, when overcap 24 is tightenedonto spinning collar 22, detent features 54, 56 provide a modestlatching force, which rotationally locks overcap 24 to spinning collar22. This latching force ensures co-rotation of spinning collar 22 andovercap 24 when overcap 24 is turned in the twist-off direction androtation of spinning collar 22 remains manually undeterred.

Spinning collar 22 is further imparted with a manual grip portion 58.Manual grip portion 58 can assume any form enabling spinning collar 22to be manually gripped or grasped from the exterior of child-resistantcontainer 10 when spinning collar cap assembly 12 is closed, as shown inFIG. 2. In the illustrated example, specifically, manual grip portion 58assumes the form of a lower peripheral flange or annular rim, whichextends from a lower peripheral edge of the annular body of spinningcollar 22. Manual grip portion 58 is thus referred to hereafter as“lower collar rim 58.” In other implementations, spinning collar 22 mayinclude a grip portion or multiple grip portions assuming various otherforms, providing that such grip portion(s) can be manually contactedwhen spinning collar cap assembly 12 is closed to prevent or at leastdeter co-rotation of spinning collar 22 with overcap 24 when turned inthe twist-off direction. If desired, the outer surface of lower collarrim 58 may be knurled or otherwise texturized to enhance user grip. Asshown most clearly in FIG. 2, lower collar rim 58 may be locatedadjacent and between lower annular shelf or ridge 38 of container body14 and the lower peripheral edge of overcap 24, as taken along axis 28when cap assembly 12 is assembled and resides in a closed state.

Spinning collar cap assembly 12 can be tailored, by design, to vary thecontour, dimensions, manual accessibility, and visibility of the gripportion of spinning collar 22 (lower collar rim 58 in the illustratedembodiment). For example, lower collar rim 58 may be dimensioned toextend radially beyond the lower peripheral edge of overcap 24 incertain embodiments. In other embodiments, lower collar rim 58 may bedimensioned to be radially recessed relative to the lower peripheraledge of overcap 24. As a still further possibility, lower collar rim 58may be imparted with an OD that is substantially equivalent to that ofthe lower peripheral edge of overcap 24. The term “substantiallyequivalent,” as appearing herein, is defined as differing by less than10%. Finally, lower collar rim 58 may be visibly exposed from theexterior of child-resistant container 10 when in an upright position. Inother implementations, overcap 24 may be able to slide alongaxis/centerline 28, within limits, when attached to spinning collar 22.Additionally, overcap 24 may be molded or otherwise fabricated toinclude a lower peripheral skirt or cuff, which extends radially beyondand overhangs collar rim 58 when cap assembly 12 is closed. The lowerperipheral skirt of overcap 24 may cover and, thus, visually obscure orhide lower collar rim 58 when child-resistant container 10 is an uprightposition. In such embodiments, a user may first slide overcap 24 upward(away from container body 14) to expose lower collar rim 58 beforeperforming the remaining cap detachment steps outlined below. Anadditional level of child deterrence is provided as a result.

Detachment of overcap 24 may be performed as follows. First, asindicated in FIG. 2, an adult user grasps or otherwise physicallycontacts the manual grip portion (lower collar rim 58) of spinningcollar 22. The adult user does this in a manner preventing spinningcollar 22 from co-rotating with overcap 24 when turned in the twist-offdirection. Depending upon the size and shape of container body 14, anadult user may prevent rotation of spinning collar 22 utilizing his orher thumb, while holding container body 14 or by simply grasping collar22 in a pinching motion. Utilizing the same hand or the other hand, theuser turns overcap 24 in the twist-off direction to detach overcap 24from collar 22 and gain access to inner cavity 16. For completeness, itis noted that overcap removal can also be achieved by holding overcap 24stationary in three-dimensional space, while rotating spinning collar 22in the twist-on direction (resulting in overcap rotation relative tocollar 22 in the twist-off direction). However, in actual practice,relatively few adult users will likely attempt to open cap assembly 12in this manner.

As noted above, thread stop feature 52 and detent features 54, 56provide a controlled latching force, which rotationally locks overcap 24to spinning collar 22 when tightened together. Ideally, this latchingforce is selected to exceed frictional forces between spinning collar 22and container neck 20, which could otherwise deter rotation of collar 22relative to neck 20 in the twist-off direction. Such a latching force,taken in conjunction with the ability of spinning collar 22 to freelyrotate relative to container neck 20 in the twist-off direction, ensurethat a child (or other user) attempting to open spinning collar capassembly 12 by grasping container body 14 without concurrently takingsteps to manually prevent rotation of spinning collar 22 will be unableto remove overcap 24. Instead, in this case, overcap 24 and spinningcollar 22 will co-rotate relative to container neck 20, while overcap 24and collar 22 remain joined. Co-rotation of overcap 24 and spinningcollar 22 may also create a diversion or decoy, which may delay furtherefforts by a child to gain access to child-resistant container 10.

After removal, overcap 24 may be reattached to container neck 20 in thefollowing manner. First, an adult user properly positions overcap 24over container neck 20; that is, such that threaded inner periphery 48of overcap 24 engages threaded outer periphery 46 of spinning collar 22.The adult user then turns overcap 24 relative to spinning collar 22 inthe twist-on direction. The user may grip lower collar rim 58 to preventrotation of spinning collar 22 when turning overcap 24 in this manner;however, this is unnecessary in the illustrated example due to theprovision of the above-described unidirectional rotational interfaceand, specifically, ratchet lugs 42, 44. When overcap 24 is fullytightened onto spinning collar 22, further rotation of overcap 24 in thetwist-on direction is prevented by thread stop 52. Detent features 54,56 may be designed to produce an audible sound or vibrational, hapticresponse (generally perceived as a “click”) signaling the user whenovercap 24 has been fully and properly tightened onto spinning collar24. This returns spinning collar cap assembly 12 to its fully closedposition and resets the child deterrent functionality of cap assembly12.

Still further levels of child deterrence may be realized by sizingand/or contouring spinning collar 22 such that collar 22 cannot bereadily gripped by relatively young children. For example, spinningcollar 22 may be imparted with an outer diameter that can be readilygripped by most adults, but which young children with smaller hands finddifficult to grasp. It has been determined that imparting spinningcollar 22 and, specifically, collar rim 58 with an outer diameter equalto or greater than about 100 millimeters is sufficient for this purpose;although the outer diameter of spinning collar 22 need not exceed thisthreshold in all embodiments. Additionally or alternatively, childdeterrence may be improved by tailoring detent features 54, 56 toprovide a predetermined resistance to turning of overcap 24 relative tospinning collar 22 in the twist-off direction, with the predeterminedresistance easily overcome by adults, but prohibitively difficult foryoung children to overcome. In yet further embodiments, child deterrencemay be enhanced through the provision of tamper evident features. Tofurther emphasize this latter point, an example of such tamper evidentfeatures will now be in conjunction with FIG. 3.

FIG. 3 illustrates an embodiment of child-resistant container 10 inwhich spinning collar cap assembly 12 is produced to include a tamperevident feature in the form of an exemplary tamper evident tear strip60. Child-resistant container 10 is illustrated isometrically on theleft side of FIG. 3, with tamper evident tear strip 60 shown in apartially removed state. Here, container body 14 and container neck 20are shown in phantom to more clearly depict spinning collar cap assembly12 and tamper evident tear strip 60. Comparatively, on the right side ofFIG. 3 in detail bubble 62, a limited portion of spinning collar capassembly 12 is shown in cross-section. As best shown in detail bubble62, tamper evident tear strip 60 may extend downwardly (toward containerbody 14) from a lower peripheral edge of overcap 24. Tamper evident tearstrip 60 is sized and positioned to physically cover orcircumferentially shroud spinning collar 22, particularly lower collarrim 58, until such time as tear strip 60 is removed by an end user;e.g., as accomplished by gripping and pulling tab 68 to reveal collar22, as indicated on the left side of FIG. 3. An end user is thusprevented from accessing spinning collar 22 and detaching overcap 24without initial removal of tamper evident tear strip 60.

In certain embodiments, tamper evident tear strip 60 may physicallyengage container neck 20 and/or container body 14. For example, asfurther shown in FIG. 3, tamper evident tear strip 60 may furtherinclude an inner peripheral lip 64, which extends inwardly from the mainbody of tamper evident tear strip 60 to engage container neck 20.Specifically, inner peripheral lip 64 of tamper evident tear strip 60engages the underside of a lower ledge portion or overhang 66, aslocated beneath annular ridge 38 of container neck 20. This provides anadditional or redundant measure preventing overcap detachment prior totear strip removal. This example notwithstanding, tamper evident tearstrip 60 may not engage container neck 20 in other embodiments and,instead, partially or wholly cover spinning collar 22 to provide thedesired tamper evident functionality. Tamper evident tear strip 60 canbe integrally formed with overcap 24 as single molded piece, withappropriate thinning or perforations to facilitate user removal of tearstrip 60. Alternatively, tear strip 60 can be produced as a discretepiece or package component, such as a shrink band seal. In furtherembodiments, spinning collar cap assembly 12 may include other types of(e.g., frangible) tamper evident features in addition to or in lieu oftamper evident tear strip 60; or cap assembly 12 may lack tamper evidentfeatures.

Accordingly, the present application provides child-resistant containersor packages having unique spinning collar cap assemblies. Theabove-described spinning collar cap assemblies can be designed toprovide relatively high levels of child deterrence, while remainingrelatively intuitive and easy-to-use for the majority of adults.Additionally, in some implementations, the spinning collar cap assemblymay be readily adaptable to snap lid neck finishes of the type utilizedin existing product lines. Embodiments of the spinning collar capassembly generally include spinning collar, which is adapted forengagement onto container neck by, for example, snap fit or interferencefit retention. An outer overcap or lid piece may thread to or otherwiseattach to the spinning collar to close the spinning collar cap assembly.When the spinning collar cap assembly is fully assembled and the overcapis closed (that is, attached to the collar), the bulk of the spinningcollar may be visibly hidden or obscured and not immediately apparent toa young child, such as a toddler. Additionally, the combination of theovercap and spinning collar may be able to co-rotate or spin freelyabout container neck in the above-described twist-off direction, whichmay create an interactive diversion deterring further attempts by achild to open the container. Through such attributes, and for the otherreasons discussed above, the disclosed spinning collar cap assembliesand, more broadly, child-resistant containers may provide effectivechild deterrent measures in regulating access to the container interiorand the contents stored therein.

While the foregoing description focuses primarily on articles ofmanufacture, namely, child-resistant containers having spinning collarcap assemblies, there has also been disclosed methods for manufacturingchild-resistant containers. Such methods for manufacturingchild-resistant containers having spinning collar cap assemblies mayentail direct fabrication of any component or components included withinthe spinning collar cap assembly, partial or complete assembly of thespinning collar cap assembly, or any combination thereof. Further, anynumber of entities can fabricate the components within the spinningcollar cap assembly, which can be produced utilizing variousmanufacturing techniques including, but not limited to, blow molding,injection molding, and additive manufacturing processes. Further, whileone of the entities responsible for fabricating components included thecap assembly will often perform the assembly process, this need notalways be the case. For example, it is possible for a first manufactureor group of manufacturers to fabricate the components included in thespinning collar cap assembly or the child-resistant container andsubsequently ship the components to a second entity for assemblypurposes. The second entity may also fill the container with its desiredcontents.

In keeping with the foregoing paragraph, a method for manufacturing achild-resistant package includes the step or process installing aspinning collar around a container neck such that the spinning collar isretained around the container neck, while remaining rotatable theretothrough a 360° ROM in a first rotational direction; e.g., theabove-described “twist-off” direction, which may be either a clockwiseor a counter-clockwise direction. An overcap or lid piece is thenattached to the spinning collar by, for example, placing a threadedinner peripheral surface of the overcap in contact with a threaded outerperipheral surface of the spinning collar and rotating the overcaprelative to the spinning collar in a second rotational directionopposite the first rotational direction. In certain embodiments, theinstallation process may entail engaging a snap lug or other projection,which extends from an inner periphery of the spinning collar, into anouter circumferential channel provided around the container neck.Additionally, installation may further entail press-fitting the spinningcollar onto the container neck such that the projection slides over aneck bead, which extends partially around an outer periphery of thecontainer neck, to engage into the outer circumferential channel.

In further instances, the above-described method for manufacturing achild-resistant package may include the step or process of selecting thecontainer neck (whether by purchase from a supplier, by independentfabrication, or by otherwise obtaining the container neck) to include aneck finish having: (i) an outer circumferential channel, (ii) a neckbead bounding an upper portion of the outer circumferential channel, and(iii) a gap in the neck bead having a first length as taken about acenterline of the container neck. Additionally, in at least someimplementations, the method may also include selecting the spinningcollar (whether by purchase, by independently fabricating, or byotherwise obtaining the container neck) to comprise a snap lug, which isreceived into the outer circumferential channel when the spinning collaris installed around a container neck and which has a second lengthgreater than the first length, as taken about a centerline of thespinning collar.

Terms such as “first” and “second” have been utilized above to describesimilar features or characteristics (e.g., rotational directions) inview of the order of introduction during the course of description. Inother sections of this Application, such terms can be varied, asappropriate, to reflect a different order of introduction. While atleast one exemplary embodiment has been presented in the foregoingDetailed Description, it should be appreciated that a vast number ofvariations exist. It should also be appreciated that the exemplaryembodiment or exemplary embodiments are only examples, and are notintended to limit the scope, applicability, or configuration of theinvention in any way. Rather, the foregoing Detailed Description willprovide those skilled in the art with a convenient road map forimplementing an exemplary embodiment of the invention. It beingunderstood that various changes may be made in the function andarrangement of elements described in an exemplary embodiment withoutdeparting from the scope of the invention as set forth in the appendedclaims.

What is claimed is:
 1. A method for manufacturing a child-resistantpackage, comprising: installing a spinning collar around a containerneck such that the spinning collar is retained around the containerneck, while remaining rotatable thereto through a 360 degree range ofmotion in at least a first rotational direction; and attaching anovercap to the spinning collar by placing a threaded inner peripheralsurface of the overcap in contact with a threaded outer peripheralsurface of the spinning collar and rotating the overcap relative to thespinning collar in a second rotational direction opposite the firstrotational direction.
 2. The method of claim 1, wherein installingcomprises press-fitting the spinning collar onto the container neck suchthat a projection, which extends from an inner periphery of the spinningcollar, engages into an outer circumferential channel provided aroundthe container neck.